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    BCMSB Final Poster Presentation

    Uploaded by

    Quentin Leitz
    This slide was printed as a 3'x4' poster, and used for the culminating poster session of Chemical Process Design (CHME-4050) at Rensselaer Polytechnic Institute in May 2016. Group members who worked on this project include Scott Altern, Katherine Clemente, Quentin Leitz, and Seth Ludwig.

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    BCMSB Final Poster Presentation

    Uploaded by

    Quentin Leitz
    65 views1 page
    This slide was printed as a 3'x4' poster, and used for the culminating poster session of Chemical Process Design (CHME-4050) at Rensselaer Polytechnic Institute in May 2016. Group members who worked on this project include Scott Altern, Katherine Clemente, Quentin Leitz, and Seth Ludwig.

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    This slide was printed as a 3'x4' poster, and used for the culminating poster session of Chemical Process Design (CHME-4050) at Rensselaer Polytechnic Institute in May 2016. Group members who worked on this project include Scott Altern, Katherine Clemente, Quentin Leitz, and Seth Ludwig.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    65 views1 page

    BCMSB Final Poster Presentation

    Uploaded by

    Quentin Leitz
    This slide was printed as a 3'x4' poster, and used for the culminating poster session of Chemical Process Design (CHME-4050) at Rensselaer Polytechnic Institute in May 2016. Group members who worked on this project include Scott Altern, Katherine Clemente, Quentin Leitz, and Seth Ludwig.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 1

    Group 11: Scott Altern, Katherine Clemente, Quentin Leitz, and Seth Ludwig

    Design Statement

    Feedstock: Corn stover due to low cost and abundance in the United States
    Plant location: Fulton, Illinois based on abundance and proximity to consumers
    Consumer: Chicago OHare International Airport 3rd largest airport in the U.S.
    Upstream: Feedstock

    Process Design

    Plantation

    Gasification
    Dried corn stover was converted to conventional Aspen components based on its elemental composition
    Solid carbon and sulfur are gasified with oxygen and steam according to a kinetic model in a CSTR
    Volatile component reactions are simulated in an RGibbs before reacting with gasification products in a CSTR

    Fischer-Tropsch Synthesis
    Gasification products undergo a water gas shift to achieve a H2:CO ratio of ~2.1:1
    Sulfur compounds and CO2 are removed by methanol absorption in the Rectisol process
    In Fischer-Tropsch Synthesis H2 and CO are converted to hydrocarbons. Modeled by a PFR based on a kinetic
    model for CO conversion and theoretical product distributions

    Refining Steps
    A rigorous crude fractionation column separates FT products for refining
    C11+ products are sent to the hydrocracker for isomerization and conversion to lower carbon numbers
    A fraction of these products are converted to aromatic compounds to meet ASTM fuel standards
    C6-C10 products are oligomerized to longer hydrocarbons
    C3-C5 are alkylated to the aromatics to reduce freezing point according to ASTM standards

    Gasification

    Transport

    Milling

    Shipped to
    facility via
    freight train

    Ground up
    before later
    processing
    steps

    Downstream: Distribution

    Conversion
    to Jet Fuel
    Gasification
    & FischerTropsch
    Synthesis

    Jet Fuel
    Distribution
    Shipped via
    freight train
    to Chicago
    OHare

    Jet Fuel
    Consumption
    Sold to airlines
    such as
    American,
    United & Delta

    Economics
    Our initial plant design was not economically feasible
    High capitals costs led us to redesign the plant to eliminate electrical generation and an air separation unit
    A sensitivity analysis was performed, which found that the economic feasibility is most sensitive to capital costs, followed by
    product sale price and jet fuel production rate
    We subsequently increased the plant throughput by a factor of 25 to take advantage of the flattening capital cost curve
    Total Fixed Capital Costs of $1.2 Billion
    Total Corn Stover Feedstock: 3.3 million tonnes/year

    Total Operating Cost:


    $358 million per year

    Total ISBL Cost:


    $582 million

    Fischer-Tropsch

    Refining (29%)
    Misc. Equip. (19%)
    Pretreatment (7%)
    Water-Gas Shift (3%)

    Feedstock (51%)
    Maintenance (12%)
    Prop. Tax (12%)
    Steam (1%)
    Water (0.18%)

    Gasification (28%)
    F-T (8%)
    Acid-Gas (6%)
    Frac Col (0.34%)

    3000

    Capital Cost (MM$)

    Corn Stover
    sourced in
    Iowa from
    local growers

    Refining

    2500
    2000
    1500
    1000
    500

    y = 4.659x0.5896
    R = 0.9325

    0
    0

    10000

    20000

    30000

    40000

    Total Revenue:
    $753 million per year

    Kerosene (59%)
    Naphtha (10%)
    Natural Gas (2%)

    Operators (14%)
    Electricity (12%)
    Catalysts (7%)
    Shipping (1%)
    Co-reactants (0.15%)

    Cumulative Cash Flow (MM$)

    Produce 9,780 bbl/day of grade A commercial jet fuel from a


    renewable corn stover feedstock via gasification and F-T Synthesis.

    Project Scoping

    Tax Credits (24%)


    Propane (5%)

    $4,000.00
    $3,500.00
    $3,000.00
    $2,500.00
    $2,000.00
    $1,500.00
    $1,000.00
    $500.00
    $0.00
    ($500.00)
    ($1,000.00)
    ($1,500.00)

    50000

    NCCF

    NPV

    Plant Size (Tonne Biomass Fed/Day)

    10

    15

    20

    Year

    Acknowledgments

    Refining Stages

    Rensselaer Polytechnic Institute


    The Chemical Engineering Dept.
    Professor Baysal
    Professor Bequette
    Professor Dalakos
    Daniel Howsmon

    All of our Chemical Engineering professors to this point:

    Professor Belfort
    Professor Chakrapani
    Professor Collins
    Professor Cramer

    Professor Dordick
    Professor Garde
    Professor Karande
    Professor Koffas

    Professor Lee
    Professor Plawsky
    Professor Tessier
    Professor Underhill

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